Fluid pressure sensor

ABSTRACT

A sensor includes a port body which defines an axial passage for receiving fluid. An electrical connector extends through an opening in the port body near a crimp portion opposite the axial passage and forms an upper seal with the port body. Within the interior of the port body, a support ring and base cover form a cavity which retains a sensing element. The sensing element is exposed to the fluid within the axial passage and determines the pressure. An annular seal is retained by the base cover. The crimp portion of the port body is crimped to provide an upper seal and apply a force on the components within the interior, pinching the annular seal between the sensing element and the base of the port body to create a lower seal.

FIELD OF THE INVENTION

The subject disclosure relates to sensing technology and moreparticularly to devices for sensing fluid pressure.

BACKGROUND OF THE INVENTION

Various pressure sensors, such as Automotive Pressure Transducers(APTs), employ Ceramic Capacitive Sense Elements (CSEs) to sensepressure. Square CSEs were developed to improve manufacturing of thesense elements, but have been limited to a maximum application pressureof around 35 bar. Further, APTs are assembled using a crimping processwhich deforms a metal pressure port wall onto a plastic base componentto retain the sensor package, load the internal seal, and create a glandinto which an environmental sealant can be dispensed.

SUMMARY OF THE INVENTION

In an example of one design, the plastic base component is split intotwo separate components, one to load the internal seal, and the secondto provide external electrical connection. Both components are requiredto be retained in the package and immobile. The internal seal and theinternal components should be reliably loaded. Due to tolerances of theseal and the components forming the gland for the seal, clearance canexist around the gland presenting locations where the seal can extrude.In high pressure systems, backup rings are frequently used as a means toprevent the extrusion of seals. The subject disclosure provides amechanism to reduce and control seal extrusion. The subject technologyovercomes many of the prior art problems associated with sensor andnon-sensor applications. In one aspect of one embodiment, the subjecttechnology relates to a pressure sensor with an improved maximumallowable pressure range which distributes loads to effectively seal thesensor while retaining all components aligned in the assembly. Thesubject technology further relates to a seal, and components forretaining the seal, which maintain an effective seal even when subjectedto high pressure and without hampering accuracy of the sensing device.

In one embodiment, the subject technology relates to a pressure sensorfor sensing the pressure of a fluid. The sensor includes a port bodywith a distal end defining an axial passage for receiving the fluid. Afirst sidewall extends from the distal end of the port body andterminates in a proximal crimp portion defining an opening. The sensorhas an electrical connector with a shoulder extending through theopening. The connector has a flexible radial flange within the portbody. Together, the electrical connector and port body define aninterior for a plurality of components. A support ring in the interiorhas an upper surface with a radially inward ledge that acts as a stopfor the shoulder and, in turn, sets a gap between the upper surface andthe flexible flange. When the proximal crimp portion is crimped down onthe flexible flange, an upper seal is formed.

The sensor can also include a base cover in the interior between thesupport ring and the axial passage. The base cover and support ring canform a cavity and retain a sense element assembly therewithin. One ormore contact pads can be disposed on a surface of the sense elementassembly. In some embodiments, the support ring is a conductive metaland the proximal crimp portion applies a loading force to the supportring, causing the support ring to maintain contact with the one or morecontact pads. In some cases, the support ring can also be a more rigidmaterial than the electrical connector, for example, so that more forceis needed to deform the support ring. In some embodiments, anenvironmental sealant is applied to a junction of the proximal crimpportion and the flexible flange.

In some embodiments, the subject technology relates to a pressure sensorwith a port body having a distal end defining an axial passage. The portbody further includes a first sidewall extending from the distal end todefine an interior. A base cover in the interior includes a side walland a skirt defining an axial bore. The skirt has a ledge extendingradially inward from the skirt and terminating in two opposing annularridges to form a recess therebetween. A sense element within theinterior is exposed to a fluid via the axial bore. An annular seal,seated at least partially within the recess, is compressed between thesense element and the port body to seal the interior from the fluid. Asa result of the opposing annular ridges, extrusion of the annular sealis beneficially reduced or prevented.

In other embodiments, the annular seal, when not compressed, has theshape of a cylindrical ring with an outer diameter and a centraldiameter. Further, the annular seal, when not compressed, can have anouter diameter that is less than a central diameter of the recess suchthat a gap is formed between the annular seal and the recess. Theopposing annular ridges can have inner diameters that are greater thanthe central diameter of the annular seal. Further, one of the opposingannular ridges can have an inner diameter that is less than the outerdiameter of the annular seal. The annular ridges can be thin such thatwhen a compression force causes the annular seal to expand radiallyoutward within the recess, the annular ridges will flex while retainingthe annular seal in the recess.

In different embodiments, the subject technology relates to an elongatedpressure sensor with a support ring. At least one axial channel extendsthrough the support ring. The pressure sensor also includes anelectrical connector with at least one latch extending into the at leastone axial channel of the support ring. A base cover with at least oneupstanding finger extends into the at least one axial channel of thesupport ring and couples with the at least one latch of the electricalconnector. In some embodiments, the sensor also includes a sense elementassembly disposed in between the base cover and the support ring. Whenthe at least one upstanding finger is coupled to the at least one latch,the electrical connector, support ring, sense element assembly, and basecover resist movement with respect to one another.

In several embodiments, the sense element assembly includes a circuitmodule coupled to a sense element, the circuit module having at leastone contact pad on an upper surface. The support ring is a conductivematerial and is also grounded. When the at least one upstanding fingeris coupled to the at least one latch, the at least one contact pad isheld in contact with the support ring to ground the circuit module.Further, each of the at least one axial channels can further includeaxial recesses in an outer sidewall of the support ring. When the atleast one finger is coupled to the at least one latch, the axialrecesses house the at least one finger and resists twisting of the basecover with respect to the support ring.

In certain embodiments, the subject technology relates to a pressuresensor with a port body defining an interior. A conductive support ringin the interior has a contact surface. A sense element assembly is alsolocated in the interior. A circuit module is electrically connected tothe sense element assembly and has at least one pad between the circuitmodule and the contact surface. The at least one pad provides anelectrical ground contact through the support ring for preventingelectromagnetic interference on the sense element assembly. In someembodiments, the conductive ring is in contact with the port body andthe port body is grounded. Further, a seal can provide a loading forceto maintain contact between the at least one pad and the support ring.In some embodiments, the support ring is symmetric around a centralplane for simplified assembly.

The subject technology also relates, in other embodiments, to anelongated pressure sensor for sensing a pressure associated with afluid. A port body includes a distal end defining an axial passage forreceiving the fluid. The port body has a first sidewall extending fromthe distal end and terminating in a proximal crimp portion that definesan opening. The pressure sensor has an electrical connector with ashoulder extending through the opening. The shoulder has a flexibleflange within the port body. Together, the electrical connector and portbody define an interior. A conductive support ring in the interior has alower contact surface and an upper surface having a radially inwardledge that acts as a stop for the shoulder and, in turn, sets a gapbetween the upper surface and the flexible flange. At least one axialchannel extends between the upper surface and lower surface of theconductive support ring. At least one latch extends distally from theelectrical connector into the at least one axial channel of the supportring. A base cover in the interior includes at least one upstandingfinger that extends proximally into the at least one axial channel ofthe support ring and couples with the at least one latch of theelectrical connector. The base cover also has a skirt defining an axialbore and having a ledge extending radially inward from the skirt andterminating in two opposing annular ridges to form a recesstherebetween. A sense element is positioned within a cavity defined bythe electrical connector, the support ring, and the base cover. Thesense element has a lower surface exposed to the fluid via the axialbore. A circuit module within the cavity is coupled to the senseelement, the circuit module having at least one contact pad touching thelower surface of the support ring. An annular seal is positioned withinthe recess, the annular seal contacting the port body, base cover, andsense element to form a lower seal between the axial passage and thecavity. Further, the proximal crimp portion is crimped down on theflexible flange to form an upper seal and apply a force to theconductive support ring. This force keeps the conductive support ring ingrounded electrical contact with the at least one contact pad to preventelectromagnetic interference on the circuit module and sense element.Further, the force ensures the annular seal is compressed to maintainthe lower seal.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those having ordinary skill in the art to which the disclosedsystem pertains will more readily understand how to make and use thesame, reference may be had to the following drawings.

FIG. 1 is a front perspective view of a pressure sensor in accordancewith the subject technology.

FIG. 2 is an exploded view of a pressure sensor in accordance with thesubject technology.

FIG. 3 is a cross-sectional view of a pressure sensor in accordance withthe subject technology.

FIG. 4 is a bottom perspective view of an electrical connector for apressure sensor in accordance with the subject technology.

FIG. 5A is a top perspective view of a support ring for a pressuresensor in accordance with the subject technology.

FIG. 5B is a bottom perspective view of a support ring for a pressuresensor in accordance with the subject technology.

FIG. 6 is a top perspective view of a sense element assembly for apressure sensor in accordance with the subject technology.

FIG. 7 is a perspective view of a base cover for a pressure sensor inaccordance with the subject technology.

FIG. 8A is a top perspective view of an electrical connector, senseelement assembly, and support ring assembled together for a pressuresensor in accordance with the subject technology.

FIG. 8B is a bottom perspective view of an electrical connector, senseelement assembly, and support ring for a pressure sensor in accordancewith the subject technology.

FIG. 9A is a top perspective view of an electrical connector, senseelement assembly, support ring, and base cover assembled together for apressure sensor in accordance with the subject technology.

FIG. 9B is a bottom perspective view of an electrical connector, senseelement assembly, support ring, base cover, and annular seal for apressure sensor in accordance with the subject technology.

FIG. 10A is a front perspective view of a pressure sensor in accordancewith the subject technology prior to being crimped.

FIG. 10B is a front perspective view of a pressure sensor in accordancewith the subject technology after being crimped.

FIG. 11 is a detailed partial cross-sectional view of the pressuresensor of FIG. 10B.

FIG. 12A is a zoomed in cross-section of an annular seal, base cover,and sense element assembly in accordance with the subject technologyprior to being crimped.

FIG. 12B is another zoomed in cross-section of an annular seal, basecover, and sense element assembly in accordance with the subjecttechnology prior to being crimped.

FIG. 12C is a zoomed in cross-section of an annular seal, base cover,sense element assembly, and port body in accordance with the subjecttechnology after the port body is crimped.

DETAILED DESCRIPTION

The subject technology overcomes many of the prior art problemsassociated with sensors. The advantages, and other features of thesystems and methods disclosed herein, will become more readily apparentto those having ordinary skill in the art from the following detaileddescription of certain preferred embodiments taken in conjunction withthe drawings which set forth representative embodiments of the presentinvention. Like reference numerals are used herein to denote like parts.Further, words denoting orientation such as “upper”, “lower”, “distal”,and “proximate” are merely used to help describe the location ofcomponents with respect to one another. For example, an “upper” surfaceof a part is merely meant to describe a surface that is separate fromthe “lower” surface of that same part. No words denoting orientation areused to describe an absolute orientation (i.e. where an “upper” partmust always be on top).

Referring now to FIG. 1, a fully assembled sensor 100 in accordance withthe subject technology is shown. The sensor 100 is well-suited forhigh-pressure environments such as automotive environments. For example,the sensor 100 can be used anywhere under the hood such as on the engineblock of a motor vehicle or equivalent to sense pressure of a particularfluid within the motor vehicle (i.e. oil, transmission fluid, cylinderpressure, or the like). It is envisioned that the sensor 100 could alsobe mounted within a transmission or outside of a transmission. It isenvisioned that the subject technology is broadly applicable to any typeof sensor.

The sensor 100 includes a port body 102 connected to an electricalconnector 104. The port body 102 includes a distal end 106 defining anaxial passage 108 for receiving a fluid. A sidewall 110 extends from thedistal end 106, terminating in a proximal crimp portion 112. Theproximal crimp portion 112 of the port body 102 and the electricalconnector 104 couple to form an upper seal around an interior asdiscussed more fully herein. The electrical connector 104 has a proximalend 126 with a female connector with pins 128 which allow a circuitmodule within the interior (See FIGS. 2 and 3) to be electricallyconnected with external components. Hardware attachment wing 122 sitswithin recess 124 of the port body 102 and allows the sensor 100 to bemechanically fixed to an external structure to hold the sensor 100 inplace.

Referring now to FIGS. 2 and 3, exploded and sectional views of a sensor100 are shown. When the sensor 100 is fully assembly (i.e. see FIG. 3),the port body 102 extends from the distal end 106 which defines theaxial passage 108 to a proximal crimp portion 112 that defines anopening 127. The electrical connector 104 has a shoulder 150 whichextends through the opening in the proximal crimp portion 112. The portbody 102 and electrical connector 104 define an interior 125 for theother components of the sensor 100.

The interior 125 encloses a base cover 130 and a support ring 140 thatdefine an interior cavity 127. The cavity 127 houses a sense elementassembly 134 which has a lower surface 188 exposed to fluid within theaxial passage 108 via an axial bore 194 within the base cover 130 (SeeFIG. 7). The sense element assembly 134 includes a circuit module 136and a sense element 138. The sense element assembly 134 forms anelectrical connection with external components via the contact pins 161.The sense element assembly 134 has the ability to sense the pressure offluid within the axial passage 108. For example, the sense element 138may include capacitive sense elements, piezoresistive elements designedto measure to flexure of a diaphragm, or the like. The circuit module136 is coupled to sense element 138 for processing, transmitting, and/orstoring signals from the sense element 138.

To help seal the cavity 127 from fluid within the axial passage 108, anannular seal 132 is provided in between a bottom surface 131 of the portbody 102, base cover 130, and sense element 138 to form a lower seal133. An upper seal 135 is also formed between the electrical connector104, the port body 102, and a support ring 140 within the interior 125of the port body 102. In some cases, an environmental sealant 148 helpsseal the parts of the upper seal together.

Referring now to FIG. 4, a bottom perspective view of the electricalconnector 104 of the sensor 100 of FIG. 1 is shown. Distal contact pins160 protrude from the electrical connector 104. The contact pins 161 arefed through sockets 180 (See FIG. 6) on the circuit module 136 to forman electrical connection. Proximal contact pins 161 extend out of theelectrical connector 104. External devices can then be connected to thecontact pins 161 to place the circuit module 136 in electricalconnection with external devices when the sensor 100 is fully assembled.

Still referring to FIG. 4, the shoulder 150 of the electrical connector104 is sized to fit within the port body 102. The shoulder 150 has aflexible flange 152 which extends around the shoulder 150. When thesensor 100 is fully assembled, the shoulder 150 extends through theopening 127 of the port body 102 and the flexible flange 152 ispositioned within the interior 125 of the port body 102. The electricalconnector 104 also has two latches 154 extending from the distal end144. As shown, the latches 154 are configured to grip an object (i.e.the support ring 140 or the base cover 130) at opposing areas. Thelatches 154 terminate in banking surfaces 156. Proximate to the bankingsurfaces 156 are detents 158 which catch a corresponding finger 196 ofthe base cover 130 (See FIGS. 3 and 7). The latches 154 are as flexibleas needed to catch the finger 196 and provide interconnection betweenthe electrical connector 104 and the base cover 130.

Referring now to FIGS. 5A and 5B, the support ring 140 is shown isolatedfrom the other components of the sensor 100. The support ring 140 issymmetric around a central plane “p” which allows for a simplifiedassembly (i.e. there is no need to align and/or join multiple parts).The support ring 140 has a proximal (or upper) surface 168 that definesat least a keyhole-shaped interior axial void 164. In some embodimentsthe interior axial void 164 is not keyhole-shaped. The axial void 164helps form the cavity 127 within which the circuit module 136 sits. Thesupport ring 140 includes an outer wall 162 with a first diameter “d1”and a first inner wall 163 with a second diameter “d2” partiallydefining the interior axial void 164. The axial void 164 is furtherdefined by a second inner wall 165 of a third diameter “d3” which alsoprovides two opposing radial ledges 166. The ledges 166 are beneath theproximal surface 168 of the support ring 140, and act as a stop for theshoulder 150 of the electrical connector 104. When the shoulder 150 isseated within the radial ledges 166, a gap 208 (See FIG. 9A) is formedbetween the proximal surface 168 and the flexible flange 152 of theelectrical connector 104. The support ring 140 also has a distal contactsurface 170 that interfaces with the sense element assembly 134.

Two axial channels 172 extend through the support ring 140 between thetop surface 168 and bottom surface 170. The axial channels 172 allow theelectrical connector 104, support ring 140, and base cover 130 to becoupled together. The latches 154 of the electrical connector 104 slidethrough the axial channels 172 to align the support ring 140 and theelectrical connector 104 and prevent the electrical connector 104 fromrotating with respect to the support ring 104. Fingers 196 from the basecover 130 also slide into the axial channels 172, further sitting withinnotches 167 in the support ring 140, and lock with the latches 154. Whenthe fingers 196 and latches 154 lock, the electrical connector 104 isheld against the proximal side of the radial ledges 166 of the supportring 140. Further, the base cover 130 holds the sense element assembly134 against the distal surface 170 of the support ring 140. In this way,connecting the latches 154 with the fingers 196 prevents significantaxial and rotational movement between the electrical connector 104,support ring 140, sense element assembly 134, and base cover 130. As aresult, assembly of the sensor 100 is easy and reliable.

The port body 102 acts similar to a Faraday cage to disallow, reduce, orminimize the influence of radio frequency and other electrical noise.The port body 102 better protects the sense element assembly 134 whenthe sensor is electrically coupled to the port body 102. Thus, thesupport ring 140 is preferably made of a conductive material to allowfor electrical coupling between the circuit module 136, sense elementassembly 134, and port body 102. The support ring 140, while necessaryto couple to the port body 102, is less impactful on actual preventionof interference than the port body 102 itself. In some embodiments, thecircuit module 136 contains contact pads 176 (See FIG. 6). When thesense element assembly 134 is held against the support ring 140, thecontact pads 176 provide improved electrical coupling to the port body102 and further prevent electromagnetic interference along the senseelement assembly 134. Notably, while two axial channels 172, two latches154, and two fingers 196 are shown, this is only by way of example.Different numbers of each of these components could be used (i.e. one,three, four, etc.) to accomplish the goals of the subject technology.

Referring now to FIG. 6, a top perspective view of the sense elementassembly 134 for the sensor 100 is shown. The sense element assembly 134includes a circuit module 136 and a sense element 138. Typically, thesense element 138 is disposed with a distal end 188 exposed to a fluidchannel (i.e. via the axial bore 108 in the port body 102). The senseelement 138 may include a ceramic substrate surrounding sub-sensingelements (not distinctly shown) for measuring pressure within the fluidchannel. For example, the sub-sensing elements may include capacitivesense elements, piezoresistive elements designed to flexure on adiaphragm, or the like. The circuit module 136 sits directly on top ofthe sense element 138 and forms an electrical connection with thesub-sensing elements, for example, via lead lines 186.

In general, the circuit module 136 has various components for receiving,processing, storing, and transmitting signals from the sub-sensingelements. For example, the circuit module 136 can be a printed circuitboard containing one or more application specific integrated circuits,or the like. When the sensor 100 is fully assembled, a proximal end 142of the circuit module 136 extends through the axial void 164 of thesupport ring 140 and attaches to a distal end 144 of the electricalconnector 104. This coupling may be mechanical. A sealant 146 seals theinterface between the contact pins 161 and the electrical connector 104.A flexible bridge 178 of the circuit module 136 allows the proximal end142 of the circuit module 136 to rotate 180 degrees or more and bendover the square end 174. One or more pins 161 of the electricalconnector 104 are soldered or otherwise engaged to one or more sockets180 on the proximal end 142 to create an electromechanical connectionbetween the pins 161 and the sense element assembly 134. Typically, theattachment of the electrical connector 104 to the sense element assembly134 is achieved through soldering.

The square end 174 of the circuit module 136 also has one or moreelectrical contact pads 176. The electrical contact pads 176 reduceunwanted electromagnetic interference to improve performance andaccuracy of the sense element assembly 134. In some cases, the supportring 140 is a conductive metal which is grounded via a connection to theport body 102 or via another connection to a grounded conductivematerial. Therefore the pads 176 can be held in contact with the supportring 140 to electrically couple the sense element assembly 134 to theport body 102 and prevent electromagnetic interference.

Referring now to FIG. 7, a top perspective view of the base cover 130for the sensor 100 is shown. The base cover 130 is circular and fitswithin the interior 125 of the port body 102. The base cover 130includes an outer side wall 206 and an inner side wall 190 that definesa rectangular recess 192 for retaining the sense element assembly 134.The inner sidewall 190 also includes an axial through bore 194surrounded by a skirt 202. The skirt 202 has a ledge 204 extendingradially inward and surrounding the axial bore 194. The ledge 204terminates in two opposing annular ridges 201, 203 to form a recess 205(see FIGS. 12A and 12B) therebetween. The recess 205 can retain anannular seal 132, as discussed more fully herein.

When the sensor 100 is fully assembled, the base cover 130 has twoupstanding fingers 196 that extend through the notches 167 of the axialchannels 172 of the support ring 140 and couple with the latches 154 ofthe electrical connector 104. The upstanding fingers 196 have shelves198 extending radially inward that catch the detents 158 of the latches154. The shelves 198 partially extend over rectangular holes 200 whichprovides additional flexibility to the fingers 196.

Referring now to FIGS. 8A and 8B, the electrical connector 104, senseassembly 134, and conductive support ring 140 are shown assembledtogether. The pins 161 of the electrical connector 104 electricallycouple to the sockets 180 of the circuit module 136. The electricalconnector 104 and the proximal end 142 of the circuit module 136 restinside the keyhole-shaped axial void 164 of the support ring 140 suchthat the proximal surface 168 of the support ring 140, acts as a stopfor the shoulder 150 of the electrical connector 104. This serves, inturn, to set a gap 208 between the proximal surface 168 of the supportring 140 and the flexible flange 152 of the electrical connector 104,prior to formation of the upper seal 135. The gap 208 gives the flexibleflange 152 space to bend when the electrical connector 104 is sealed tothe port body 102, as described more fully herein.

The latches 154 of the electrical connector 104 extend through the axialchannels 172 of the support ring 140. The banking surfaces 156 anddetents 158 of the latches 154 are visible through the axial channels172 and are positioned to catch the fingers 196 of the base cover 130.The flexible bridge 178 of the circuit module 136 allows the square end174 of the sense element assembly 134 to bend along arrow “a” such thatthe four electrical pads 176 electrically contact the support ring 140and prevent electromagnetic interference.

Referring now to FIGS. 9A and 9B, the electrical connector 104, senseassembly 134, conductive support ring 140, annular seal 132, and basecover 130 are shown assembled together. The annular seal 132 restsinside of the base cover 130 and presses upon the lower surface 188 ofthe sense element assembly 134. The fingers 196 of the base cover 130extend through the notches 167 in the axial channels 172 of the supportring 140, and catch the latches 154 of the electrical connector 104. Thefingers 196 and the latches 154 coupling together, as well as theirlocation within the axial channels 172 and notches 167, keeps theassembled parts of FIGS. 9A and 9B together by resisting axial androtational movement.

Referring now to FIGS. 10A, 10B and 11, a crimping technique can be usedto form an upper (or proximate) seal 135 on the sensor 100. FIG. 10Ashows the sensor 100 in a position where the parts have been assembledbut the upper seal 135 has not been formed. On the other hand, FIGS. 10Band 11 show the sensor 100 with an upper seal 135 that has been formedby crimping (the process of creating a crimp), as described herein.

As discussed above, the shoulder 150 of the electrical connector 104 isseated, within the interior 125 of the port body 102 on a ledge 166 ofthe support ring 140. The flexible flange 152 of the electricalconnector sits above the support ring 140 but still within the interior125 of the port body 102. Prior to crimping, the port body 102 has aproximal crimp portion 112 which is shaped like a hollow cylinder with auniform inner diameter at the top at the top of the port body 102 (FIG.10A). When the user wishes to create an upper seal 135, a crimpingdevice is employed to force proximal crimp portion 112 of the port body102 radially inward and down. The proximal crimp portion 112 folds intothe flexible flange 152 of the electrical connector 104 and forms theupper seal between the electrical connector 104, the support ring 140,and the port body 102 (See FIG. 3). An environmental sealant 148 can beapplied between the port body 102 and the electrical connector 104, aspart of the upper seal 135, to further ensure an effective seal.Preferentially, the location of sealant 148 is above the flexible flange152, between the port body 102 and the electrical connector 104. Duringthe crimping process, the flexibility of the flexible flange 152 allowsfor the majority of the compression force to transfer to the supportring 140 as the crimp portion 112 contacts the support ring 140. Thesupport ring 140 is made from a more rigid material than the electricalconnector 104 (i.e. metal versus plastic) such that the support ring 140bears the brunt of the compression load. For example, the support ring140 can be made from a material that, as compared to the electricalconnector 104, requires a much a greater load (more force) to deform alike distance. Additionally, the force between the flexible flange 152and the metal crimp portion 112 of the port body 102 is small, butpreferably large enough to prevent ingress of the environmental sealant148 when dispensed and cured.

The upper seal 135 acts to seal the interior 125 of the port body 102.The upper seal 135 includes the proximal crimp portion 112 of the portbody 102 that serves the purpose of holding other components of thesensor 100 in close proximity to one another. For example, the proximalcrimp 112 can be a rigid material and, when crimped to form the upperseal 135, holds the electrical connector 104, support ring 140, senseelement assembly 134, and base cover 130 between the proximal crimp 112and a lower surface 131 of the port body 102. This prevents significantmovement between the components to ensure minimal wear and longevitywhen the pressure assembly 100 is moved or handled. Further, the forceprovided by the proximal crimp 112 helps hold the contact pads 176 ofthe circuit module 136 in contact with the support ring 140 to provideelectrical coupling to the port body 102 for the sense element assembly134. The upper seal 135 also includes the environmental sealant 148 toprovide additional sealing.

Referring now to FIGS. 12A-12C, the force exerted during the crimpingprocess on the support ring 140 to form the upper seal 135 also causescompression of the lower annular seal 132 to form a tight seal betweenthe port body 102, base cover 104, and sense element 138 around theaxial passage 108 as the compression force is transmitted by the supportring 140 and to a lesser extent the electrical connector 104. Becausethe support ring 140 is stronger than the plastic electrical connector104, the crimp force applied to the support ring 140 can be relativelygreater. As a result, more effective compression of the sensor 100components together, which enables a better electrical connectionbetween the support ring 140 and the pads 176 of the sense elementassembly 134 can occur. FIGS. 12A and 12B show the annular seal 132 inposition within the base cover 130 prior to the crimping around theupper seal 135 taking place. FIG. 12C shows the annular seal 132 afterthe crimping takes place, the force of the crimping having deformed andpressed the lower annular seal 132 into contact with the base surface131 of the port body 102 around the axial passage 108.

Initially, the annular seal 132 sits within the recess 205 in the basecover 130, defined between opposing annular ridges 201, 203. Whenuncompressed, the annular seal 132 is shaped like a toroidal orcylindrical ring. The upper annular ridge 201 slopes slightly axiallyinward from a central portion 207 within the recess 205 to create theouter boundary wall of sealing gland and help retain the annular seal132. In some embodiments a straight cylindrical sidewall is thepreferred interior shape of ridge 201, as sloping may reduce sealingpotential. The lower annular ridge 203 slopes from the central portion207 at a sharper slope than the upper annular ridge 201 to provide aseat for the annular seal 132 and retain the annular seal 132 in thesensor 100 assembly during manufacture. Optionally, at a narrowest point211 of the skirt 202, the lower annular ridge 203 has a diameter “D1”that is less than an outer diameter “D2” of the annular seal 132 butgreater than a central diameter “D3” of the annular seal 132. Thesmaller diameter D1 of the lower annular ridge 203 as compared to thelarger outer diameter D2 of the annular seal 132 allows the base cover130 to hold the annular seal 132 in place within the recess 205 andprevent the seal 132 from slipping out the axial bore 194. Meanwhile,since the diameter D2 of the lower annular ridge 203 is greater than thecentral diameter D3 of the annular seal 132, the bottom 139 of theannular seal 132 extends below the bottom of the base cover 130 (i.e.the bottom 139 of the annular seal 132 protrudes slightly through theaxial bore 194). Upon crimping, the base 131 of the port body 102 isflush with the annular seal 132 and the distal end of the base cover 130comes in contact with the base 131 of the port body 102 to form thelower seal 133. Notably, the slopes and dimensions shown are by way ofexample. In other embodiments, any of the slopes and dimensionsassociated with one annular ridge 201, 203 can be realized by the otherannular ridge 201, 203.

As described above, once the crimping force is applied, the annular seal132 is compressed between the sense element 138, base cover 130, andbase 131 of the port body 102 to form the lower seal 133 (See FIG. 12C).Typically, the annular seal 132 is formed from a material that is moreeasily compressed than the base cover 130 (i.e. rubber compared to aharder plastic), such that the annular seal 132 will deform in responseto a compression force before the base cover 130. However, the rampshape created by the annular ridges 201, 203 which form the recess 205acts to minimize the flexure when the seal 132 is compressed. Forexample, as shown in FIG. 12C, the force applied from the crimpingprimarily causes the annular seal 132 to be pinched between the senseelement 138 and the base 131 of the port body 102. This force causes theheight of the annular seal 132 to be compressed. Initial axialcompression of the seal 132 expands the seal 132 radially mostlyoutward, but also inward. As the seal 132 is compressed axially, theannular seal 132 to expands radially and fills the gap 213 between theannular seal 132 and the recess 205 within the base cover 130. Furtheroutward radial expansion of the seal 132 is limited by the annularridges 201, 203 of the base cover 130. Since volume is still conserved,the seal 132 continues to expand inward. The upper annular ridge 201compresses or crushes due force exerted from the crimped portion 112 ofthe port body 102 via the support ring 140 and sense element 138. Insome embodiments the upper annular ridge 201 does not flex toward theport body, such that any force required to cause flexion is removed fromthe interface between the seal 132 and the port body 102, increasing theability of the sensor 100 assembly to seal. In some embodiments annularridge 203 has no impact on extrusion. Presence of the annular ridge 201prevents extrusion of annular seal 132 because the annular ridge 201allows for a smaller gap than would otherwise be possible due totolerancing. The annular ridges 201, 203 work to retain the annular seal132 within the base cover 130 even after compression and avoid extrusionof the annular seal 132. This helps provide a reliable seal between thefluid in the axial passage 108 and the interior 125 of the port body102. Notably, formation of the lower seal 133 is discussed as a resultof the crimping force, the components discussed are equally effective atproviding a seal when other compression forces are applied to pinch theannular seal 132 and/or hold the components (i.e. the base cover 130,annular seal 132, sense element 138, and/or port body 102) together.

In another embodiment, an assembly for sealing a passageway exposed tofluid flow is described. This assembly contains a first body, a secondbody, and an annular seal. The first body includes a distal end definingan axial passage, a first sidewall extending from the distal end todefine an interior, and a skirt defining an axial bore. The skirtcontains a ledge that extends radially inward from the skirt andterminates in two opposing annular ridges to form a recess therebetween.The annular seal is seated at least partially within the recess. Whenthe annular seal is compressed between the first and second bodies, theinterior of the passageway is sealed from the fluid. In some embodimentsthe first body is the port body and the second body is the senseelement. The assembly for sealing a passageway can be used to seal itemssuch as pipes or other fluid containing passageways. The assembly forsealing a passageway is particularly advantageous at high pressures,where a mismatch of tolerances at the flanges of the passageway couldresult in risk of seal extrusion.

In one embodiment the sensor 100 described above utilizes a lower costceramic capacitive sense element while significantly increasing theallowable pressure sensing of up to at least 70 bar (whereas prior artdevices are typically only capable of sensing pressure up toapproximately 35 bar). Further the sensor is just as accurate and cansense pressure in at least as large of a range. In another embodiment,sensor 100 is designed for 70 bar, but is applicable at higher bar suchas 100 bar.

It will be appreciated by those of ordinary skill in the pertinent artthat the functions of several elements may, in alternative embodiments,be carried out by fewer elements or a single element. Similarly, in someembodiments, any functional element may perform fewer, or different,operations than those described with respect to the illustratedembodiment. Also, functional elements (e.g., electronics, pressuresensing elements, seals, and the like) shown as distinct for purposes ofillustration may be incorporated within other functional elements in aparticular implementation.

While the subject technology has been described with respect topreferred embodiments, those skilled in the art will readily appreciatethat various changes and/or modifications can be made to the subjecttechnology without departing from the spirit or scope of the subjecttechnology. For example, each claim may depend from any or all claims ina multiple dependent manner even though such has not been originallyclaimed.

1-20. (canceled)
 21. An assembly for sealing a passageway with a fluidpassing therethrough, the assembly comprising: a) a port body 102having: i) a base surface 131; ii) an axial passage 108 for receivingthe fluid; iii) and an interior 125; b) a base cover 130 located in theinterior and in contact with the port body, the base cover having: i) askirt defining an axial bore; and ii) a ledge extending radially inwardfrom the skirt, wherein the ledge terminates in: a lower annular ridge201, having a diameter D1; and an upper annular ridge 203 that forms arecess 205 with the lower annular ridge, wherein the lower annular ridgeopposes the upper annular ridge; and c) an annular seal 132 having anouter diameter D2 and a central diameter D3, such that D2 is larger thanD1 and D1 is larger than D3 for holding the annular seal within therecess such that the annular seal extends below the axial bore of thebase cover, wherein the annular seal is capable of deforming and beingin contact with the base surface at times a crimping force is applied tothe assembly, wherein the lower annular ridge slopes from a centralportion at a sharper slope than the upper annular ridge to reduce aflexure of the annular seal at times the crimping force is applied tothe assembly.
 22. The assembly of claim 21, further comprising a senseelement in the interior so that the annular seal is compressed betweenthe base surface and the sense element to seal around the axial bore.23. The assembly of claim 21, wherein the annular seal expands radiallyto fill a gap between the annular seal and the recess at times acrimping force is applied.
 24. The assembly of claim 21, wherein theannular seal is formed from a material that is more easily compressedthan the base cover.
 25. The sensor of claim 21, wherein the upper ridgecompresses due to the force.
 26. A sensor for sensing a pressureassociated with a fluid comprising: a port body 102 including: a basesurface 131; a distal end defining an axial passage for receiving thefluid; and a first sidewall extending from the distal end; an electricalconnector 104, wherein the electrical connector and port body define aninterior 125; a base cover 130 located in the interior and including askirt terminating in two opposing ridges that define a recess; a senseelement located in the interior, the sense element having a lowersurface exposed to the fluid via the axial passage; a circuit modulelocated in the interior and coupled to the sense element; and an annularseal 132 in the recess between the lower surface and the port body thatdeforms when a force is applied to the sense element, wherein the skirtreduces and controls extrusion of the annular seal.
 27. The sensor ofclaim 26, wherein the first sidewall terminates in a proximal crimpportion that defines an opening and the force is a compressive forcecreated by crimping the crimp portion.
 28. The sensor of claim 26,wherein prior to application of the force, a gap is formed between theannular seal and the recess, and after application of the force, the gapis filled by initial deformation of the annular seal but furtherradially outward expansion is limited by the two opposing annularridges, subsequent deformation of the annular seal is substantiallyradially inward.
 29. The sensor of claim 26, wherein an upper ridge ofthe two opposing annular ridges compresses due to the force.
 30. Thesensor of claim 26, wherein an upper ridge of the two opposing annularridges does not flex such that the force component to cause flexion isremoved from an interface between the annular seal and the port body.31. A sensor for sensing a pressure associated with a fluid comprising:a port body 102 including: a base surface 131; a distal end defining anaxial passage for receiving the fluid; and a first sidewall extendingfrom the distal end; an electrical connector 104, wherein the electricalconnector and port body define an interior 125; a base cover 130 locatedin the interior and including a skirt terminating in two opposing ridgesthat define a recess; a sense element located in the interior, the senseelement having a lower surface exposed to the fluid via the axialpassage; a circuit module located in the interior and coupled to thesense element; and an annular seal 132 in the recess between the lowersurface and the port body that deforms when a force is applied to thesense element, wherein the skirt provides a seat for the annular seal toretain the annular seal.
 32. The sensor of claim 31, wherein the firstsidewall terminates in a proximal crimp portion that defines an openingand the force is a compressive force created by crimping the crimpportion.
 33. The sensor of claim 31, wherein prior to application of theforce, a gap is formed between the annular seal and the recess, andafter application of the force, the gap is filled by initial deformationof the annular seal but further radially outward expansion is limited bythe two opposing annular ridges, subsequent deformation of the annularseal is substantially radially inward.